A tie system is provided for use with a wall form for a cementitious backup wall and for use with a wall tie to connect between the cementitious backup wall and a veneer. The tie system includes a backup wall connector and a form connector. The form connector is connectable to the form and secures the backup wall connector in position as the wall form is filled.
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1. A tie system for use with a penetrable wall form for a cementitious backup wall that is prepared from pourable cementitious material that is poured into the wall form and for use with a wall tie to connect between the cementitious backup wall and a veneer, the tie system comprising:
(a) a form connector;
(b) a tie connector; and,
(c) a longitudinally extending backup wall connector having first and second opposed longitudinally extending sides that are generally planar and being shaped to extend through an aperture in the wall form, and having a forward-facing form-connector engagement surface and a rearward-facing form-connector engagement surface that are positioned to directly engage the form connector to substantially prevent forward and rearward relative movement between the backup wall connector and the form connector.
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This invention claims priority as a divisional of U.S. patent application Ser. No. 11/554,207, filed Oct. 30, 2006 now U.S. Pat. No. 8,051,621 issued Nov. 8, 2011, the specification of which is incorporated by reference herein.
This invention relates to a tie system and method for connecting a veneer to a back-up wall. In a particularly embodiment, the invention relates to a tie system and method for connecting a veneer made from bricks or the like to a backup wall made from a cementitious material that is formed using a form made from a penetrable material such a foam material.
Certain types of building incorporate a backup wall that is made from a cementitious material and a veneer that may be made from rows of bricks or the like. The cementitious backup wall is sometimes poured on-site into a form that may be made from slabs of foam material.
Connectors are typically used to secure the veneer to the backup wall. However, these connectors sometimes move out of position during the pouring of the cementitious material that makes up the backup wall, thereby potentially impacting their ability to function as desired. For example, the connector may not be properly positioned to secure the veneer in place once the cementitious material cures.
In accordance with the instant invention, a system and method are provided to secure a veneer to a backup wall constructed from a pourable material. The system includes a form connector that is securable, and preferably removably securable, to a wall form. In accordance with such an embodiment, the form connector is secured in position and may accordingly be used to secure a backup wall connector in place while the pourable material is curing and, more preferably, until the pourable material is cured, or is at least essentially cured. In a particularly preferred embodiment, the form connector secures the backup wall connector in place while the pourable material is placed, e.g., poured into, the wall form and during at least a sufficient portion of the during process such that the backup wall connector is secured in position by the pourable material.
In another embodiment, a wall tie, which is used to secure a veneer to a backup wall, is connected to the backup wall connector with the form connector in position. In such an embodiment, the form connector remains in position when the veneer wall is installed.
In an alternate embodiment, the form connector is removed prior to the veneer wall being installed, thus permitting the form connector to be reused.
In an alternate embodiment, the engagement member that is used to secure the form connector to the backup wall connector is also used to secure the wall tie to the form connector. Such an embodiment is particularly preferred in those embodiments wherein the form connector is removed prior to the veneer wall being installed.
Accordingly, in accordance with one embodiment of the instant invention, there is provided a tie system for use with a penetrable form for a cementitious backup wall and for use with a wall tie to connect between the cementitious backup wall and a veneer, the tie system comprising:
(a) a backup wall connector shaped to extend through an aperture in the form and having:
(b) a tie connector; and,
(c) a form connector connectable to the form.
In one embodiment, the tie system further comprises a forward-facing wall-tie-engagement surface and a rearward-facing wall-tie-engagement surface that are positioned to engage the wall tie to substantially prevent forward and rearward relative movement between the wall tie and the backup wall connector.
In another embodiment, the forward-facing form-connector-engagement surface is the same as the forward-facing wall-tie-engagement surface, and wherein the rearward-facing form-connector-engagement surface is the same as the rearward-facing wall-tie-engagement surface.
In another embodiment, the backup wall connector has a connector aperture defined by a connector aperture wall, wherein the connector aperture wall comprises the forward-facing and rearward-facing form-connector-engagement surfaces.
In another embodiment, the backup wall connector has a connector aperture defined by a connector aperture wall, wherein the connector aperture wall comprises the forward-facing and rearward-facing wall-tie-engagement surfaces.
In another embodiment, the backup wall connector is a substantially planar plate.
In another embodiment, the backup wall connector has at least one opening having a perimeter wall and the forward-facing backup-wall-engagement surface and the rearward-facing backup-wall-engagement surface comprise the perimeter wall.
In another embodiment, the backup wall connector extends other than along a linear axis. For example, the backup wall connector may have an end portion positioned within the cementitious material (when the form is filled) that is bent (e.g. about 90°) of the backup wall connector may be distorted (e.g., S shaped or corrugated) thereby increasing the surface area in contact with the cementitious material and creating a profile the resists the connector from being pulled outwardly from the cured cementitious material.
In another embodiment, the form connector is penetrable to permit a nail to be driven therethrough into the form.
In another embodiment, the form connector is made from a material selected from the group consisting of wood and polymeric material.
In another embodiment, the backup wall connector is shaped to at least substantially prevent leakage of cementitious material out of the aperture in the form.
In another embodiment, the form connector is removable connectable to the form.
In accordance with the instant invention, there is also provided a tie system for use with a penetrable form for a cementitious backup wall comprising cementitious material and for connecting between the cementitious backup wall and a veneer, comprising:
In another embodiment, the tie system further comprises a wall tie.
In another embodiment, the backup wall connector has a connector aperture positioned to engage the form connector to at least substantially prevent forward and rearward relative movement between the backup wall connector and the form connector.
In another embodiment, the connector aperture is positioned to engage the wall tie to at least substantially prevent forward and rearward relative movement between the wall tie and the backup wall connector.
In another embodiment, the backup wall connector is configured to inhibit the backup wall connector being pulled outwardly from the cementitious when the cementitious has cured by being a substantially planar plate that has at least one aperture in the portion of the backup wall connector that is positioned in the cementitious material. Alternately, the backup wall connector may extend in other than along a linear axis
In another embodiment, the form connector is penetrable to permit a nail to be driven therethrough into the form.
In another embodiment, the form connector is removable connectable to the form.
In accordance with the instant invention, there is also provided a method of securing a veneer to a backup wall comprising:
In one embodiment, the method further comprises filling the wall form with cementitious material and removing the form connector from the wall form and the form connector engagement member prior to attaching the wall tie to backup wall connector.
In another embodiment, the method further comprises constructing the wall form from foam.
In another embodiment, the method further comprises filling the wall form with cementitious material and permitting the cementitious material to cure prior to removing the form connector from the wall form.
In another embodiment, the method further comprises filling the wall form with cementitious material prior to attaching the wall tie to the second portion.
In another embodiment, the method further comprises selecting a backup wall connector wherein the first portion has at least one form-connector-engagement surface.
For a better understanding of the present invention and to show clearly how it may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, in which:
Reference is made to
Referring to
Referring to
The plate may be made from corrosion resistant steel, or from some other suitable material having a suitable thickness. Preferably, the backup wall connector 24 does not have any flanges or the like extending outwardly from first and second sides 40, 42. As the backup wall connector 24 is inserted through the form 18 (e.g., by hammering it on its rearward end 38), it creates a form aperture 34 (see
It will be understood that a sectional view of the backup wall 12 and the form 18 are shown in
Referring to the back up wall connector 24 exemplified in
Referring to
It is not necessary for the forward-facing surface 48 to face directly forwardly. Thus, it is not necessary for the forward-facing surface 48 to be vertical or to have any portion that is vertical. The forward-facing surface 48 may have any shape that faces forwardly at least somewhat. It may be curved, linear, or a combination of both. Similarly, it is not necessary for the rearward-facing surface 50 to face directly rearwardly and therefore it is not necessary for the rearward-facing surface 50 to be vertical. The rearward-facing surface 50 may have any shape that faces rearwardly at least somewhat, and may be curved, linear or a combination of both.
In the exemplary embodiment shown in
In another exemplary embodiment shown in
The backup wall connector 24 may have a plurality of forward-facing surfaces 48 instead of one. The backup wall connector 24 may have a plurality of rearward-facing surfaces 50 instead of one. For example, the backup wall connector may have a plurality of apertures and the apertures may be positioned on any portion of the backup wall connector 24 that will be positioned in the cementitious material 16 when the cementitious material 16 is cured.
In a further alternate embodiment, It will be appreciated that backup wall connector 24 may alternately have sides 40 and 42 that are not planar, e.g., they may be S shaped, corrugated or have a portion that extends laterally outwardly (e.g. bent laterally with respect to the longitudinal axis of backup wall connector 24, i.e. the axis defined by a line passing through forward end 36 and rearward end 38).
Referring to
The connecting aperture 56 is preferably sized to concurrently or subsequently (i.e., after form connector 26 is removed) receive the wall tie 30 (
It will be understood that a sectional view of the backup wall 12 and the form 18 are shown in
Instead of having a single connector aperture 56, as shown in
The connector aperture 56 is shown in
Referring to
The form connector 26 may be connected to the form 18 in any suitable way. For example, the form connector 26 may be secured to, and preferably removably secured to, the form 18 by fasteners 28 which may be, for example, nails or screws. In this scenario, the form connector 26 may be made from a relatively soft material that is relatively easily penetrated by a nail being hammered therethrough. For example, the form connector 26 may be made from a polymeric material (e.g., plastic), or wood.
The assembly shown in
Referring to
After removal of the form connector 26 (
The first end 66 connects to the connector aperture 56. The forward-facing and rearward-facing wall tie surfaces 58 and 60 preferably cooperate with the first end 66 to substantially prevent forward and rearward movement between the backup wall connector 24 and the wall tie 30, and therefore between the backup wall connector 24 and the veneer 14.
The second end 68 of the wall tie 30 connects to the veneer 14 in any suitable way known in the industry. For example, it may be buried in mortar between adjacent rows of veneer elements 22.
Referring to
It is preferable for the connecting aperture 56 to be a closed aperture, as shown in
Referring to
The penetrable form 18 may be made from a polymeric foam material, such as the foam material that it is used currently in slabs to make a form at certain construction sites. Such foam material is penetrable by means such as a nail. Additionally, such foam material can be left in the erected structure to act as an insulation material. It is alternatively possible, however, to make the form out of some other material that is penetrable by a fastener such as a nail.
The structure of the backup wall connector 24 may be selected to permit it to be manufactured inexpensively. For example, the backup wall connector 24 shown in
The structure of the form connector 26 may be selected to permit it to be manufactured inexpensively. For example, the form connector 24 shown in
It is possible that the tie system 10 (
It will be understood that various modifications and adaptations of the embodiments shown herein can be made without departing from the present invention, the scope of which is defined in the appended claims.
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